Corner guard

ABSTRACT

A corner guard system and method for waterproofing or flashing a corner intersection in a window, door or other opening, corner joint or other intersection structure. The corner guard in includes a base and an end piece. The base has first and second members joined along a ridge edge at an angle to substantially conform to the shape of the corner intersection. The end piece is joined along an end piece edge with the base at an angle to substantially conform to the shape of the opening ledge and adjacent opening surface. The present invention provides an economical, simple to install and easy to use corner guard as an alternative to the traditional flashing membrane while demonstrating significant advantages in minimizing drafts and water leaks in residential and commercial construction.

PRIORITY CLAIM

This application claims priority to U.S. Provisional Application No.60/494,635, filed Aug. 12, 2003, which application is herebyincorporated by reference in its entirety as if fully set forth herein.

FIELD OF THE INVENTION

This invention relates generally to a system and method for effectivelyand efficiently waterproofing and flashing corner or joint intersectionsduring construction and, more specifically, to a corner guard and asystem and method of installing a corner guard for waterproofing andflashing corner intersections in windows, doors or other openings oralong wall, floor or ceiling joints.

BACKGROUND OF THE INVENTION

It is necessary to waterproof and flash at critical areas around theexterior of residential or commercial buildings in construction to avoidpotential water damage, mold and mildew. Construction personnelpresently use one of a number of different methods in an effort towaterproof and flash corner or joint intersections during construction.These methods typically incorporate peel and stick membranes that areoften times difficult and inefficient to install.

FIGS. 1A through 1C show an example of the installation of a prior artself-adhering, self-sealing, flexible flashing membrane applied toconstruction to minimize drafts and water leaks. A frequent example ofthe type of corner joint or intersection is a window, door or otheropening from the exterior to the interior of a structure. Commonelements in this situation include an opening 10 defined by an openingsurface 12, an interior ledge 14 and corner joints 16. Around a roughwindow, door or other opening, the flashing membrane is installed asmultiple strips that are preferably folded and stapled over the framingto cover over the sill/jam inside corners.

With reference to FIG. 1A, a flashing membrane strip 20 is installed byplacing the membrane strip against surface 12. The membrane strip 20 istypically attached using staples or nails along the top edge, forexample at points 22. With reference to FIG. 1B, a second flashingmembrane strip 24, cut approximately the width of the opening plusadditional fold-over width and length, is installed by placing thesecond membrane strip along the ledge 14 b, folding the excess widthover the ledge onto the surface 12, and folding the excess length alongthe adjacent ledge 14 a. With reference to FIG. 1C, a corner joint wing26, cut approximately the depth of the corner joint 16 plus additionalfold-over length, is secured along corner joint 16 with excess lengthfolded over along surface 12.

This complicated process is frequently confusing and subject to error.Incorrectly overlapping or layering the flashing membrane over time notonly fails to prevent, but in fact may increase potential water damage,mold and mildew.

Thus, there is a need for a corner guard and a system and method forinstalling a corner guard that addresses the disadvantages associatedwith current waterproof and flashing procedures.

SUMMARY OF THE INVENTION

The preferred embodiment of the present invention provides a cornerguard for corner joints or intersections in building construction thatincludes a base and an end piece. The base has first and second membersjoined together at an angle with respect to each other between first andsecond ends of the base. The end piece is joined at the first end of thebase adjacent the first and second members of the base. The end pieceand the first and second members of the base are joined at an angle asbetween the end piece and each member, respectively.

In an alternative embodiment, a system incorporating the presentinvention includes an opening defined by a surface, at least twointerior ledges and at least one corner joint at the intersection of thetwo interior ledges. A corner guard is provided that includes a base andan end piece. The base has first and second members joined together atan angle with respect to each other between first and second ends of thebase. This angle is substantially the same as the angle defined by theintersection of the two interior ledges forming the corner joint. Theend piece is joined at the first end of the base adjacent the first andsecond members of the base. The end piece and the first and secondmembers of the base are joined at an angle as between the end piece andeach member, respectively. This angle is defined by the intersection ofthe ledges and the surface.

An alternative embodiment is directed to a system for waterproofing orflashing corner intersections in windows, doors or other openings thatincludes an opening defined by a surface, at least two interior ledgesand at least one corner joint at the intersection of the at least twointerior ledges; a first membrane strip; a means for securing the firstmembrane strip to the surface; a corner guard for waterproofing orflashing the at least one corner intersection having a base with offirst and second members joined together, the base having first andsecond ends, where the first and second members of the base are joinedbetween the first and second ends at an angle substantially the same asthe angle defined by the intersection of the two interior ledges formingthe corner joint, and an end piece joined at the first end of the baseadjacent the first and second members of the base, wherein the end pieceand the first and second members of the base are joined at an angledefined by the intersection of the ledges and the surface; means forsecuring the corner guard along the intersection of the at least twointerior ledges at the corner joint; a second membrane strip; and meansfor securing the second membrane strip along one of the at least twointerior ledges and the surface and overlapping at least part of thebase and end piece of the corner guard.

An alternative embodiment is directed to a method for waterproofing orflashing a corner intersection in a window, door or other openingdefined by a surface, at least two interior ledges and at least onecorner joint at the intersection of the at least two interior ledges.The steps include placing a first membrane strip against the surface;securing the membrane strip to the surface; placing a corner guard alongthe intersection of the at least two interior ledges at the cornerjoint, wherein the corner guard includes a base made up of a first andsecond member joined together, the base having first and second ends,wherein the first and second members of the base are joined between thefirst and second ends at an angle with respect to each other, and an endpiece joined at the first end of the base adjacent the first and secondmembers of the base, wherein the end piece and the first and secondmembers of the base are joined at an angle as between the end piece andthe first and second members, respectively; securing the corner guardalong the corner joint; placing a second membrane strip along one of theat least two interior ledges and the surface and overlapping at leastpart of the base and end piece of the corner guard; and securing thesecond membrane strip to the at least two interior ledges and thesurface.

In yet an alternative embodiment, a corner guard includes a first sheetof material; a second sheet of material fixed to and substantiallytransversely intersecting the first sheet of material; and a third sheetof material fixed to and substantially transversely intersecting thefirst and second sheets of material, wherein the first and second sheetsof material do not extend beyond the intersection with the third sheetof material.

As will be readily appreciated from the foregoing summary, the inventionprovides an economical, simple to install and easy to use corner guardas an alternative to the traditional flashing membrane whiledemonstrating significant advantages in minimizing drafts and waterleaks in residential and commercial construction.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred and alternative embodiments of the present invention aredescribed in detail below with reference to the following drawings:

FIGS. 1A through 1C illustrate the prior art procedure for applyingself-adhering, self-sealing, flexible flashing membrane to roughwindows, doors or other openings to minimize drafts and water leaks.

FIGS. 2 through 4 are isometric views of the corner guard in accordancewith the present invention.

FIGS. 5A through 5C illustrate the procedure for applying the cornerguard to rough windows, doors or other openings in accordance with thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of the present invention provides aneconomical, simple to install and easy to use corner guard as analternative to the traditional flashing membrane. The present inventionoffers significant advantages in minimizing drafts and water leaks inresidential and commercial construction.

The present invention may be used with any type of corner joint orintersection on structures where waterproofing or flashing to minimizedrafts and water leaks is of value. For example, the corner guard may beused with hand rail caps, deck railing, floor-to-posts, exterior housingstructural elements such as roof-to-wall intersections, skylights, deckscuppers or other externally exposed structural corner joints orintersections. The present invention is preferably for use inassociation with rough window, door or other opening defined by anopening surface, interior ledges and corner joints, and is described inrelation to this particular preferred application.

Referring to FIGS. 2 through 4, the preferred embodiment of a cornerguard 100 in accordance with the present invention consists of a base102 and an end piece 104. The base 102 is comprised of a first member106 and a second member 108 joined or formed along a ridge edge 110 soas to form a substantially ninety degree angle. The end piece 104 isjoined or formed along an end piece edge 112 of the base 102 to formanother ninety degree angle. The base first and second members and endpiece are preferably substantially flat, sheet materials, made of aplastic or metal substance susceptible to heat welding, gluing,extrusion or forming into the desired corner guard shape.

Most windows, doors or other openings demonstrate an approximatelyninety degree angle at corner joints as well as between the ledge andthe opening surface. However, the precise angle to which the first andsecond members are aligned may vary depending on the shape of the cornerjoint for which the corner guard is to be used. Similarly, the preciseangle to which the end piece and base are aligned may vary depending onthe shape of the opening surface and its relationship to the ledge ofthe opening.

The base 102 is variable in length, dependent primarily upon the depthof the interior ledge. In the preferred embodiment, the base 102 isbetween seven and eight inches deep. This allows the preferred cornerguard to be adjustably fit on window and rough door openings ofdifferent depths. Extra length of the base 102 can be easily removedduring installation, as necessary. The preferred size and shape of theend piece 104 varies based on the size and configuration of the interiorledge and opening surface with which it is used.

The corner guard of the present invention is used with window, door orother openings by placing the corner guard along an interior ledge ofone or more corner joints, preferably in conjunction with complementaryflashing membrane material. The preferred methodology for installationof the corner guard of the present invention is shown with reference toFIGS. 5A through 5C as used in association with a rough window, door orother opening 10 defined by an opening surface 12, interior ledges 14and corner joints 16.

With reference to FIG. 5A, a flashing membrane strip 120 is installed byplacing the membrane strip against the opening surface 12. The membranestrip 120 is preferably attached by stapling or nailing the membranestrip 10 along the top edge, for example at points 122.

As shown in FIG. 5B, the corner guard 100 is installed along theinterior ledge 14 b at corner joint 16 a. More specifically, the base102 of the corner guard is placed along the corner joint 16 a such thatthe first member 106 is adjacent the ledge 14 a, second member 108 isadjacent ledge 14 b, ridge edge 110 is aligned along corner joint 16 aand end piece 104 overhangs ledges 14 a and 14 b to rest adjacentsurface 12, preferably exterior to membrane strip 120. The corner guardis preferably secured along the ledge 14 a or 14 b using nails in thefirst member 106 or second member 108 or both, depending on the openingconfiguration and user preference. Alternative means of securing thecorner guard may be used, such as tacks, staples, pins, screws,adhesives or other equivalent securing options. The base 102 of thecorner guard may be cut along the edge opposite the end piece 104 to fitthe depth of the particular window, door or other opening. This processis repeated by installation of a second corner guard along the interiorledge at corner joint 16 b.

As shown in FIG. 5C, the methodology continues with the installation ofa second flashing membrane 124 along ledge 14 b. The second flashingmembrane 124 is cut approximately the width of the opening plusadditional fold-over width, preferably at least two inches. The secondflashing membrane 124 is installed by placing the second membrane alongthe ledge 14 b, folding the excess width over the ledge onto the surface12 and including the end pieces 104 of the corner guards installed atcorner joints 16 a and 16 b, below the ledge 14 b.

Substantially the same method outlined above may be repeated to installthe corner guard at additional corner joints of opening 10. As describedabove, the corner guard may be used with alternative types of cornerjoints or intersections on structures where waterproofing or flashing tominimize drafts and water leaks is of value, for example, with hand railcaps, deck railing, roof-to-wall intersections, skylights, deck scuppersor other externally exposed structural corner joints or intersections.In alternative applications, the corner guard may not be used inconjunction with flashing membrane. In these configurations, the base102 or end piece 104 may be trimmed or sized to fit and secured to otherstructures having one or more corner joint or intersection of wall,floor, roof or post elements. FIGS. 6 through 8 provide several examplesof alternative types of corner joints or intersections on structure withwhich the present invention may be used. In each of these embodimentsthe corner guard may be secured to the surface structure using nails,tacks, staples, pins, screws, adhesives or other equivalent securingoptions. Also, in each example, the corner guard may be used with orwithout other flashing materials, such as flashing membrane strips.

FIG. 6 illustrates use of the present invention at the intersection of ahalf-wall with a vertical wall. In FIG. 6, a half-wall 150 intersectswith a substantially vertical wall 152. A side surface 154 of thehalf-wall intersects vertical wall 152 at joint 158. A top surface 156of the half-wall intersects vertical wall 152 at joint 160. A secondside surface 162 of the half-wall opposite side surface 154 intersectsvertical wall 152 at joint 164.

A corner guard 100 a is installed along the top surface 156 and sidesurface 154 at joints 158 and 160. More specifically, the first member106 a of the base of the corner guard is placed adjacent side surface154, the second member 108 a of the base is placed adjacent top surface156, and the end piece 104 a is placed adjacent vertical wall 152,substantially fitting joints 158 and 160. If desired, a corner guard 100b is installed along the top surface 156 and side surface 162 at joints164 and 160. More specifically, the first member 108 b of the base ofthe corner guard is placed adjacent side surface 162, the second member106 b of the base is placed adjacent top surface 156, and end piece 104b is placed adjacent vertical wall 152, substantially fitting joints 164and 160.

FIG. 7 illustrates use of the present invention at the intersection ofvertical walls and a floor. In FIG. 7, a first wall 170 intersects witha second wall 172 at corner joint 174. The first wall 170 and the secondwall 172 intersect with a floor 176 at joints 178 and 180, respectively.A corner guard 100 is installed along the intersection of the first andsecond walls and the floor. More specifically, the first member 106 ofthe base of the corner guard 100 is placed adjacent the wall 172, thesecond member 108 of the base is placed adjacent the wall 170, and endpiece 104 is placed adjacent the floor 176 such that the angle betweenthe first member 106 and the end piece 104 is substantially the same asthe angle between the second wall 172 and the floor 178 at joint 180 andthe angle between the second member 108 and the end piece 104 issubstantially the same as the angle between the first wall 170 and thefloor 176 at joint 178.

FIG. 8 illustrates use of the present invention with a scupper, forexample on a deck. In FIG. 8, a scupper 180 intersects with a floor 182at joints 184 and 186. A corner guard 100 a is installed along joint 184by placing the first member 106 a of the base of the corner guard 100 aadjacent an inner wall 188 of the scupper, the second member 108 a ofthe base is placed adjacent the floor 182, and end piece 104 a is placedadjacent a wall 190 associated with the scupper. In this embodiment,part of the end piece 104 a is removed to facilitate proper fit alongjoint 184. If desired, a corner guard 100 b is installed along joint 186by placing the second member (not shown) of the base of the corner guard100 b adjacent an inner wall (not shown) of the scupper, the firstmember 106 b of the base is placed adjacent the floor 182, and end piece104 b is placed adjacent a wall 190 associated with the scupper. In thisembodiment, part of the end piece 104 b is removed to facilitate properfit along joint 186.

The present invention overcomes limitations associated with theinstallation of a traditional flashing membrane and provides aneconomical, simple to install and easy to use corner guard to waterproofand flash corner intersections in window, door or other openings.

While the preferred embodiment of the invention has been illustrated anddescribed, as noted above, many changes can be made without departingfrom the spirit and scope of the invention. For example, while thepreferred use of the corner guard of the present invention is along thelower ledge of windows or doors, it can equally be used along otherparts of windows, doors or openings, wherever protection from drafts andwater leaks is of value. Likewise, while the corner guard is preferablyused prior to casement of a window, door or other opening, the presentinvention may be used in the absence of opening casements. In addition,while the base and end pieces of the corner guard are preferably formedas part of a unitary construction, the same elements could be connectedin a variety of way to achieve the desired shape and function, forexample, by tacks, staples, pins, screws, adhesives or other equivalentsecuring options. Also, while the preferred first and second members ofthe base and end piece were described as generally flat, the materialsheets need not be flat, but could include shape, for example, curvatureor designs. Accordingly, the scope of the invention is not limited bythe disclosure of the preferred embodiment. Instead, the inventionshould be determined entirely by reference to the claims that follow.

1. A corner guard for corner joints or intersections in buildingconstruction, comprising: a base comprised of first and second membersjoined together, the base having first and second ends, wherein thefirst and second members of the base are joined at an angle with respectto each other between the first and second ends; and an end piece joinedat the first end of the base adjacent the first and second members ofthe base, wherein the end piece and the first and second members of thebase are joined at an angle as between the end piece and each member,respectively.
 2. The corner guard of claim 1, wherein the angle betweenthe first and second members is substantially between 85 and 135degrees.
 3. The corner guard of claim 1, wherein the angel between theend piece and each member, respectively, is substantially between 85 and135 degrees.
 4. A system for corner joints or intersections in buildingconstruction, comprising: an opening defined by a surface, at least twointerior ledges and at least one corner joint at the intersection of theat least two interior ledges, wherein a corner joint angle is defined bythe intersection of the at least two interior ledges forming the cornerjoint and a surface ledge angle is defined by the intersection of atleast one of the ledges and the surface; and a corner guard forwaterproofing or flashing the at least one corner intersection,comprising: a base comprised of first and second members joinedtogether, the base having first and second ends, wherein the first andsecond members of the base are joined between the first and second endsat an angle with respect to each other substantially the same as thecorner joint angle; and an end piece joined at the first end of the baseadjacent the first and second members of the base, wherein the end pieceand the first and second members of the base are joined at an angle asbetween the end piece and the first member substantially the same as thesurface ledge angle.
 5. The system of claim 4, wherein one of the atleast two interior ledges of the opening has a depth and the length ofat least one of the first and second members of the base issubstantially the same as the depth of the one of the at least twointerior ledges.
 6. The system of claim 4, wherein the corner jointangle defined by the intersection of the at least two interior ledgesforming the corner joint is substantially between 85 and 135 degrees. 7.The system of claim 4, wherein the surface ledge angle is defined by theintersection of at least one of the ledges and the surface issubstantially between 85 and 135 degrees.
 8. A system for corner jointsor intersections in building construction, comprising: an intersectionwherein a first and second surface intersect to form a first jointdefining a corner joint angle and the first surface intersects with athird surface to form a second joint defining a surface angle; and acorner guard for waterproofing or flashing the intersection, comprising:a base comprised of first and second members joined together, the basehaving first and second ends, wherein the first and second members ofthe base are joined between the first and second ends at an angle withrespect to each other substantially the same as the corner joint angle;and an end piece joined at the first end of the base adjacent the firstmember of the base, wherein the end piece and the first member of thebase are joined at an angle as between the end piece and the firstmember substantially the same as the surface angle.
 9. The system ofclaim 8: wherein the surface intersects with a fourth surface to form athird joint defining a second surface angle; and further comprising anend piece joined at the first end of the base adjacent the second memberof the base, wherein the end piece and the second member of the base arejoined at an angle as between the end piece and the second membersubstantially the same as the second surface angle.
 10. A system forwaterproofing or flashing corner intersections in windows, doors orother openings, comprising: an opening defined by a surface, at leasttwo interior ledges and at least one corner joint at the intersection ofthe at least two interior ledges, wherein a corner joint angle isdefined by the intersection of the at least two interior ledges formingthe corner joint and a surface ledge angle is defined by theintersection of at least one of the ledges and the surface; and a firstmembrane strip; means for securing the first membrane strip to thesurface; a corner guard for waterproofing or flashing the at least onecorner intersection, comprising: a base comprised of first and secondmembers joined together, the base having first and second ends, whereinthe first and second members of the base are joined between the firstand second ends at an angle with respect to each other substantially thesame as the corner joint angle; and an end piece joined at the first endof the base adjacent the first and second members of the base, whereinthe end piece and the first and second members of the base are joined atan angle as between the end piece and the first member substantially thesame as the surface ledge angle; means for securing the corner guardalong the intersection of the at least two interior ledges at the cornerjoint; a second membrane strip; and means for securing the secondmembrane strip along one of the at least two interior ledges and thesurface and overlapping at least part of the base and end piece of thecorner guard.
 11. The system of claim 10, wherein one of the at leasttwo interior ledges of the opening has a depth and the length of atleast one of the first and second members of the base is substantiallythe same as the depth of the one of the at least two interior ledges.12. The system of claim 10, wherein the corner joint angle defined bythe intersection of the at least two interior ledges forming the cornerjoint is substantially between 85 and 135 degrees.
 13. The system ofclaim 10, wherein the surface ledge angle is defined by the intersectionof at least one of the ledges and the surface is substantially between85 and 135 degrees.
 14. A method for waterproofing or flashing a cornerintersection in a window, door or other opening defined by a surface, atleast two interior ledges and at least one corner joint at theintersection of the at least two interior ledges, comprising: placing afirst membrane strip against the surface; securing the membrane strip tothe surface; placing a corner guard along the intersection of the atleast two interior ledges at the corner joint, wherein the corner guardcomprises: a base comprised of first and second members joined together,the base having first and second ends, wherein the first and secondmembers of the base are joined between the first and second ends at anangle with respect to each other; and an end piece joined at the firstend of the base adjacent the first and second members of the base,wherein the end piece and the first and second members of the base arejoined at an angle as between the end piece and the first and secondmembers, respectively; securing the corner guard along the corner joint;placing a second membrane strip along one of the at least two interiorledges and the surface and overlapping at least part of the base and endpiece of the corner guard; and securing the second membrane strip to theat least two interior ledges and the surface.
 15. The system of claim14, wherein the corner guard is placed along the corner joint such thatthe first member of the base is adjacent one of the at least two ledgesof the opening and the second member of the base is adjacent the otherone of the at least two ledges of the opening.
 16. The system of claim14, wherein one of the at least two interior ledges of the opening has adepth and the length of at least one of the first and second members ofthe base is cut along the edge opposite the end piece to fit the depthof the one of the at least two interior ledges.
 17. The system of claim14, wherein the first and second members of the base are joined along aridge so as to form an angle between the first and second members ofsubstantially between 85 and 135 degrees.
 18. The system of claim 14,wherein the end piece and the first and second members of the base arejoined as between the end piece and each member, respectively, at anangle of substantially between 85 and 135 degrees.
 19. A corner guardfor flashing a corner joint or intersection of a building structure,comprising: a first sheet of material; a second sheet of material fixedto and substantially transversely intersecting the first sheet ofmaterial; and a third sheet of material fixed to and substantiallytransversely intersecting the first and second sheets of material,wherein the first and second sheets of material do not extend beyond theintersection with the third sheet of material.
 20. The corner guard ofclaim 19, wherein the intersection between the first and second sheetsform an angle substantially between 85 and 135 degrees.
 21. The cornerguard of claim 19, wherein the intersection between each of the firstand second sheets and the third sheet, respectively, forms an anglesubstantially between 85 and 135 degrees.
 22. The corner guard of claim19, wherein the sheets of material are substantially flat.